Beam Cutting Control Rules for Material Waste Reduction
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Solution Overview
Problem
Beam cutting technologies face significant material waste and inefficiencies due to ineffective part placement methods and technology rules, leading to high material and machine costs, as well as challenges in minimizing piercings, position distances, and cutting distances.
Innovation Solution
Implementing a set of controlling rules that allow for the formation of clusters of parts with micro joints, optimized tool radius compensation, and strategic turning areas, enabling closer part positioning and reduced waste by minimizing the number of piercings and adjusting cutting distances based on material and technology variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional nesting part placement methods are used to position parts on material, then parts can be arranged in a structured manner, but significant material waste occurs with 20-50 percent waste
Solution Approach 1:
The cutting process is segmented into multiple phases: rough cutting phase where parts are cut with larger safety distances, and finish cutting phase where parts are cut with minimal safety distances. This segmentation allows the system to first ensure structural integrity during rough cutting, then optimize material usage during finish cutting, thereby reducing overall material waste while maintaining cutting efficiency
Solution Approach 2:
The system performs preliminary rough cutting operations to create initial part separations and establish basic geometry. This preliminary action allows subsequent finish cutting operations to proceed with tighter tolerances and smaller safety distances, maximizing material utilization without compromising the reliability of the cutting process
2Reliability
If safety distances of 5-20 mm are maintained between parts during cutting, then reliable cutting process is ensured, but material waste increases
Solution Approach 1:
The safety distance is made dynamic rather than static. During rough cutting phase, larger safety distances (5-20 mm) are maintained to ensure cutting process reliability and prevent part damage. During finish cutting phase, the safety distance is dynamically reduced to minimal values, thereby minimizing material waste while maintaining reliability when it matters most
3Manufacturing precision
If tool radius compensation is changed during cutting, then accurate part dimensions are achieved, but cutting process is interrupted requiring new piercings
Solution Approach 1:
The system maintains continuous cutting action by coordinating tool radius compensation changes with the cutting path. Instead of stopping and restarting the cutting beam when compensation changes are needed, the system continuously moves the cutting head while adjusting compensation parameters, thereby maintaining manufacturing precision without incurring time losses from interruptions and re-piercings
4Loss of substance
If parts are positioned very close to each other to minimize waste, then material utilization improves, but number of piercings and position distances increase
Solution Approach 1:
The cutting operation is segmented into rough cutting and finish cutting phases, each with different positioning strategies. During rough cutting, parts are positioned with standard safety distances, keeping operations simple. During finish cutting, parts are repositioned with minimal distances to maximize material utilization. This segmentation allows the system to achieve high material utilization without permanently increasing operational complexity
Solution Approach 2:
The system changes key parameters including safety distances, tool radius compensation values, and cutting path coordinates between rough and finish cutting phases. These parameter changes enable parts to be positioned very close together during finish cutting to minimize material waste, while the system manages the increased complexity through automated parameter adjustment rather than manual intervention
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes material waste, optimizes machine costs, and ensures a reliable cutting process with improved part quality by reducing unnecessary piercings and position distances, while allowing for complex part combinations and efficient cutting operations.
Implementation Method 1
laser cutting
Implementation Method 2
plasma cutting
Implementation Method 3
ion beam cutting
Implementation Method 4
flame or torch cutting
Implementation Method 5
water cutting
Data Source
AI summary
The present invention relates to a method and a system for machine cutting several parts (31, 32, 33, 34) out of a piece of material using a beam cutting technology. The invention provides a set of controlling rules and variables for cutting two dimensional shapes or patterns. One rule or a combination of several rules are used for the cutting operation depending on the shape or pattern to be cut, the shape or pattern forming the parts (31, 32, 33, 34) out of the piece of material. The present invention specifically teaches that the set of controlling rules comprises rules for the forming of a cluster (3A) of parts with free form shapes, the parts being positioned so close to each other so that only the thickness of one cut from the cutting beam is found between adjacent parts whenever the shape of the parts allows it.